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VSM Examples

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    Engineering

    Management

    Learning to See Parts IV, VA Value Stream Mapping Workshop

    Mike Rother & John Shook

    Lean Enterprise Institute

    MSE507

    Lean Manufacturing

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    Value Stream MappingWorkshop Goals

    To understand the complete value stream To introduce Value Stream Mapping VSM!

    To dra" a current state map

    # Learn the mapping concepts and icons

    To $e a$le to design an improved value stream# %evelop the a$ilit to 'see the (lo") o( a value stream

    To dra" a (uture state map

    # Learn the mapping concepts and icons

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    Value Stream MappingTopics

    Topic Page# *vervie"

    # The Process Steps +-!

    # The Process Step . /ase Stud!

    # The Process Step 0!

    # The Process (Step 6) 4

    # The Process (Step 6 Acme Stamping Case Stu!) "5

    # The Process (Steps 7#$) 45

    # The Process (Step %0) 5&

    # Conc'usions 54

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    Value Stream Step 1Draw the Future State Map

    TE P*P+SE2

    3ighlight sources o( "aste

    Eliminate them

    In a short period o(time,

    TE -+AL2 To $uild a chain o( production "here the individualprocesses are linked to the customers! either $ continuous (lo"

    the $est! or pull and each process gets as close as possi$le to

    producing onl "hat the customers! need "hen the need it4

    5hat can "e do "ith "hat "e have6

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    Value Stream Map /urrent State

    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+

    8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .

    EE/L SCE1LE

    Lead Time -. %as

    0 das+ sec

    >41 das

    - min

    +4: das

    +0 min

    84> das

    1> min

    .40 das

    . min

    8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+

    8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .

    EE/L SCE1LE

    Lead Time -. %as

    0 das+ sec

    >41 das

    - min

    +4: das

    +0 min

    84> das

    1> min

    .40 das

    . min

    8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    /ompetitive LT 7 - das

    Takt Time 7 +:48 min

    /ustomer %ataOn-Time Delivery

    %emand 7 .0Dda

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+

    8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das+ sec

    >41 das

    - min

    +4: das

    +0 min

    84> das

    1> min

    .40 das

    . min

    8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    Ra" 7 0 das

    5IP 7 +84+ das

    ?H 7 140 das

    Inventor

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+

    8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das+ sec

    >41 das- min

    +4: das+0 min

    84> das1> min

    .40 das. min

    8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    Touch Time 7 :B min

    ?lo" o( Valueea! Time

    Lead Time 7 8-41 das

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+

    8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das+ sec

    >41 das- min

    +4: das+0 min

    84> das1> min

    .40 das. min

    8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    /T 1>! Takt Time +:!

    /onstraintsOTD" ea! Time

    MaF 5ip 7 >41 das

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das

    + sec>41 das

    - min+4: das

    +0 min84> das

    1> min.40 das

    . min8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    /* 7 8- min

    /* 7 /hangeover

    Setup TimesO# Margin" ea! Time

    /* 7 + hour

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das

    + sec>41 das

    - min+4: das

    +0 min84> das

    1> min.40 das

    . min8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    MaintenanceOTD" ea! Time

    9ptime 7 >=;

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das

    + sec>41 das

    - min+4: das

    +0 min84> das

    1> min.40 das

    . min8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    Gualit?T@ 7 1>;

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    /ustomer

    %emand 7 .0 per da

    8 shi(ts

    Stamping

    -.8

    /T7+sec

    /o7+ hr4

    9ptime7:0;

    S4 5eld < +

    /T7- min

    /o7+= min4

    9ptime7>=;

    I

    I

    I

    I/oils0 das

    /T7 +0 min

    /o7= min4

    9ptime7+==

    ;8 shi(ts

    /T7 1> min

    /o7 8- min

    ?T@ 7 1>;8 shi(ts

    ShippingI

    I:+8=8+88

    Assem$l Test

    B=

    +C

    %ail

    B=D1=D-= da

    ?orecasts

    *rder Entr

    Production

    /ontrol

    MRP

    1 5EE

    ?orecast

    Suppliers 5eekl&

    ?aF

    .EE/L SCE1LE

    Lead Time -. %as

    0 das

    + sec>41 das

    - min+4: das

    +0 min84> das

    1> min.40 das

    . min8 das

    Lead Time

    78-41 das

    + shi(t+ shi(t

    /T7 . min

    /o7=

    9ptime7+==

    ;8 shi(ts

    /ompetitive Lead Time

    7 - %as

    Takt Time

    7 +:48 Minutes

    *rdersDda

    7 -1

    Gueue

    7 +40 %as

    Touch Time

    7 :B min

    5hat is the pitch time6

    ?lo" o( ValueOTD" ea! Time

    5ho is setting the pace6

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    The *((ice

    *((ice (unctions support man shop (loor value streams purchasing, paroll

    The rate o( customer demand is o(ten hard to see

    Inventor can $e (orms, paper"ork, in$askets, out$askets,

    voicemail, email

    /cles o( activit o(ten are random little standard "ork

    /on(usion a$out "ho the customer is and "hat is value

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    The *((ice

    +.E2E*3 TE

    +ECT2E S T+

    ELMATE .ASTE8

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    The *((ice /urrent State

    %e(ine $oundaries o( our value stream 'There has to $e a productK or serviceK to (ollo" like a

    purchase order or paroll document other"ise use a normal

    (lo"chart) LEI!

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    The *((ice /urrent State

    5hat capa$ilit do ou provide6 Is the demand sta$le6

    # I( not, "hat is the range 6

    5hat is the customers eFpectation o( per(ormance6

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    /onstructing *((ice /urrent State

    5aiting should $e recorded i( there is no apparent endK takt

    time and the neFt process is (ar a"a

    9se /cle Time o( customer process to understand total leadtime

    I

    Outbox

    1 Day

    w

    Waiting

    1/2 Day at

    meeting

    I

    Inbox

    1 Day

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    /onstructing *((ice /urrent State

    State StreetAssem$lCustomer

    Ma9e notes :here !ou see

    o;

    Man! Signatures

    Paper ?orm *e:or9>

    ncomp'ete 1ata

    State StreetAssem$lSupp'ier

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    1 sales Rep

    State StreetAssemblyMichigan Steel

    CompanyCustomer

    CustomerCentral

    database

    Engineering

    database

    I

    Outbox

    2 files

    1 Day

    w

    Waiting

    1/2 Day atmeeting

    I

    Inbox

    2 files

    1 Day

    I

    Outbox

    3 files

    1 Day

    w

    Waiting

    1/2 DayCustomer

    I

    Inbox

    10 files1 Day

    I

    Outbox

    4 files

    1 Day

    w

    Waiting

    I

    Inbox

    2 files

    1 Day

    w

    Waiting

    1/2 Dayur!"asing#uote

    I

    Inbox

    $ files1 Day

    Clarify1 Day

    I

    %mail /&oi!email

    W

    'eeting3 "ours

    4 %stimates

    () "ours

    *otal 10 Days*otal C* + "rs 20 min

    ,0 min3 "rs 20 min4 "rs10 min

    () "r 3 "r 1 Day () Day 1 Day 1 Day () Day 1 Day() Day 1 Day 1 Day 1 Day 1 Day

    Or-erRe!eipt

    'anf(%ng(Re&iew

    .uoterep

    O'

    ali-ation

    1 ales Rep1 %ng( 1 %ng(1 sales Rep

    %mail.uoteDesign

    Log file

    PhoneClarification

    Email-Clarification

    EmailOrder

    PhoneClarification

    PhoneClarification

    /onstructing *((ice /urrent State

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    Product ?amil

    Plan &

    Implementation

    /urrent State

    %ra"ing

    ?uture State

    %ra"ing

    Value Stream Step 1Draw the Future State Map

    %esigning a Lean ?lo"# @ou al"as need a (uture state

    # 9se pencil, update regularl, >=;

    correct is (ine

    # asis (or "ork plan $lueprint

    # egin $ dra"ing a current state

    # +st iteration assumes using eFisting

    euipment, onl minor purchases

    # 9se the list o( (uture state uestions

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    Value Stream Step 1Future State Map - $cons

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    Value Stream Step 1Future State Map % &uestion '

    .hat is the ta9t time for the chosen prouct fami'!@ .0= minutes per shi(t D B units per shi(t7 0= minutes

    3o"ever this includes no time (or euipment do"ntime,

    changeovers, or scrap and re"ork4

    9ntil these are under control ou can decide to produce

    (aster than Takt

    Its purpose is to snchroniNe the pace o( production "ith

    the pace o( sales

    A diagnostic tool to test (or overproduction

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    Value Stream Step 1Future State Map % &uestion (

    Shou' !ou ;ui' to a finishe goos Supermar9et or irect'!to shipping@

    uilding directl to shipping is ideal4

    I( the competitive lead time is less than our process lead

    time, ou "ill need a (inished goods supermarket4

    I( customer demand rises an fa''s unpreicta;'!it might

    $e $etter to use a (inished goods Supermarket4

    The cost o( holding some (inished goods ma "ell $e less

    than the cost o( eFtra capacit

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    Value Stream Step 1Future State Map % &uestion )

    .here can !ou introuce continuous f'o:@

    Produce one piece at a time

    Reduce $atch siNes and implement material replenishment4

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    Value Stream Step 1Future State Map % &uestion *

    .here :i'' !ou nee to use supermar9et pu'' s!stems@ atching might $e necessar

    5here changeo

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    Value Stream Step 1Future State Map % &uestion +

    At :hat sing'e point :i'' !ou scheu'e prouction@ This is called thepacema9erprocess4

    3o" ou control the production here sets the pace (or all o(

    the upstream processes4

    An process a(ter the pacemaker process must $e

    continuous (lo" no Supermarkets or pulls do"nstream o(

    the pacemaker process4

    There(ore, the pacemaker process is (reuentl the most

    do"nstream continuous(lo" process in the value stream4

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    Value Stream Step 1Future State Map % &uestion ,

    o: :i'' !ou 'e

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    Value Stream Step 1Future State Map % &uestion

    .hat increment of :or9 :i'' !ou consistent'! re'ease an

    ta9e a:a! at the pacema9er process@

    Start $ releasing sma'' consistent amounts at the

    pacema9erprocess, "hile simultaneousl taking a"a eual

    amounts o( (inished goods or 'paced "ithdra"al)

    This consistent increment o( "ork is called the PTC

    /an $e $ased on pac9out container uantit

    Esta$lishes interval (or monitoring status o( production

    The ke is to create a preicta;'e f'o:"hich ena$les ou to

    act uickl to pro$lems4

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    A tool used to $ some is the heiunka $oF! A load leveling $oF "ith a column (or an$an slots (or each

    PIT/3 interval and a ro" o( an$an slots (or each product tpe4

    The $oF indicates $oth the uantit produced and the time

    allocated to make it $ased on TAT time!

    Value Stream Step 1Future State Map % &uestion - .ei/unka 0o1

    Tpe

    A

    Tpe

    Tpe

    /

    : :4+= :48= :4-= :4.= :40=

    an$an

    card A

    an$an

    card /

    B4== B4+=

    an$an

    card A

    an$an

    card A

    an$an

    card

    an$an

    card

    an$an

    card

    an$an

    card /

    *ne column pDpitchpitch7+= min4

    *ne ro" per

    product

    tpe

    an$ans

    responded

    to (rom le(t

    to right at

    pitch

    increments

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    Value Stream Step 1Future State Map % &uestion - Sample

    Tpe

    A

    Tpe

    Tpe /

    : :4+= :48= :4-= :4.= :40=

    an$an

    card A

    an$ancard /

    B4== B4+=

    an$an

    card A

    an$an

    card A

    an$an

    card

    an$an

    card

    an$an

    card

    an$ancard /

    /ustomerreuirement

    Shipping

    .

    +

    -

    8

    Pacemakerprocess

    %rop an$an

    at process

    Pick up one

    (inished

    uantit

    Move (inished

    parts to

    supermarket

    Pick up

    neFt

    kan$an

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    Value Stream Step 1Future State Map % &uestion 2

    .hat process impro

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    Value Stream Step 1Future State Map % &uestion Summary

    5hat is the takt time6

    5ill "e $uild to shipping or to a supermarket6

    5here can "e use continuous (lo"6

    5here do "e have to use supermarket pull sstems6

    At "hat single point in the production chain do "e triggerproduction6

    5hat levels o( "ork "ill "e release and take a"a (rom the

    pacemaker process6

    3o" "ill "e level the production miF at the pacemaker

    process6

    5hat supporting improvements "ill $e necessar6

    e4g4 uptime, setup, training!

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    GuiN 0/ircle the $est ans"er

    %, /an;an cars are use to>

    A4 Improve (lo" $ providing "orking instructions to the neFt operator4 /ontrol the lot siNe o( a ?I?* lane so that inventor doesnKt $uild

    /4 Allo"s the operators to sort the cards into 'right siNed) $atches tominimise changeovers

    %4 Provides an instruction that regulates the seuence and timing o(production

    &, .hen ca'cu'ating ta9t time>A4 Include lunches and $reaks in the availa$le "orking time and reduce

    them a(ter"ards

    4 Include lunches and $reaks $ut do not include planned maintenance

    /4 %o not include lunches, $reaks or planned machine maintenance asavaila$le "orking time

    %4 %o not include lunches, $reaks, estimated machine do"ntime, and another unavaila$le production time

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    ACME StampingCase Stu!

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    Value Stream Step 1Future State Map % Acme 3o4 51ample

    ?irst 2ie: of the ?uture#State map Sho:ing

    Ta9t Time3 .e'BAssem;'! Ce''3 an the

    ?inishe#-oos Supermar9et

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    Value Stream Step 1Acme 3o4 Future State % 'stView

    Stamping

    Takt=60 sec.

    C/T=56 sec.

    C/O= 0

    Uptime=100%l

    2 shifts

    5eld& Ass

    L

    R Shipping

    Staging

    +C

    %ail

    State St.

    Assembl

    1!"#00 pcs/m$

    12"000 &'(

    6"#00 &)(

    T*a=20 pcs.

    2 Shifts

    Qotice that on this ?utureState Map the (our"elding and assem$l process $oFes have $een

    com$ined into one process $oF to indicate the

    continuous (lo"4 A small sketch o( a cell inside the

    process $oF also indicates the cellular

    manu(acturing concept4

    S S 1

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    Value Stream Step 1Acme 3o4 Future State % (n!View

    Secon 2ie: of the ?uture#State Map

    Sho:ing Stamping an *a: Materia'

    Supermar9ets

    V l St St 1

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    Value Stream Step 1Acme 3o4 Future State

    Signal or atch kan$an

    The stamping process needs to produce $atches larger than 1=

    pieces4

    A trigger point is set up in the stamping supermarket "hich

    includes changeover, replenishment dela and other stamping

    pro$lems4 In this case stamping "ill keep +40 das o( parts in its

    supermarket

    A signa'an$an is sent to the stamping process "henever the

    num$er o( $ins remaining drops to a trigger minimum ! level

    V l St St 1

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    Value Stream Step 1Acme 3o4 Future State

    .hat a;out *a: Materia'@ To $uild a plant level value stream the ?uture State must also

    sho" a third supermarket at the receiving dock "hich holds

    coils o( steel Acme can attach an internal "ithdra"al an$an to each coil

    and send these an$ans to their o"n production controldepartment "henever another coil is used4

    Production control can order coils $ased on their actual usage

    instead o( a $est guess determined $ MRP The cards are then returned to the receiving dock as a signal (or

    shipments that are due4 Milk runs (or dail deliveries should $e considered at this point

    Value Stream Step 1

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    Stamping

    Takt=60 sec.

    C/T=56 sec.

    C/O= 0

    Uptime=100%l

    2 shifts

    5eld& Ass

    L

    R Shipping

    Staging

    +C

    %ail

    State St.

    Assembl

    1!"#00 pcs/m$

    12"000 &'(

    6"#00 &)(

    T*a=20 pcs.

    2 Shifts

    8=

    +40 das

    $atch

    $in

    /oils

    PR*%9/TI*Q/*QTR*L

    State St.

    Assembl

    15EE

    ?orecast

    %ail

    *rder

    +C

    %ail

    coil

    coil

    at the press!

    Value Stream Step 1Acme 3o4 Future State % (n!View

    V l St St 1

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    Value Stream Step 1Acme 3o4 Future State % )r!View

    Third ?inal! vie" o( the ?uture State Map

    Sho"ing Load Leveling, /hangeovers, and Timeline

    V l St St 1

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    The material handler pulls the an$ans out o(

    the leveling $oF one$one at the PIT/3increment and moves tras o( $rackets (rom

    the (inished goods supermarket to the

    staging area one$ one according to the

    "ithdra"al an$an4

    Production

    /ontrol

    %ail *rders

    $in$in

    $in

    *C*C

    5EL%&ASS@

    L

    R

    $inShipping

    Staging

    Load Leveling oF

    Value Stream Step 1Acme 3o4 Future State

    Value Stream Step 1

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    Stamping

    Takt=60 sec.

    C/T=56 sec.

    C/O= 0

    Uptime=100%l

    2 shifts

    5eld& Ass

    L

    R Shipping

    Staging

    +C

    %ail

    State St.

    Assembl

    1!"#00 pcs/m$

    12"000 &'(

    6"#00 &)(

    T*a=20 pcs.

    2 Shifts

    +40 das

    $atch

    $in

    /oils

    PR*%9/TI*Q

    /*QTR*L

    State St.

    Assembl

    15EE

    ?orecast

    %ail

    *rder

    +C

    %ail

    coil

    coil

    at the press!

    +,+= 1 shift.

    +,+ -10 min..

    change

    over

    5eld

    change

    over5elder

    uptime

    + sec4

    +40 das

    + da

    +1: sec

    8 das

    Production Leadtime7 .40 das

    Processing Time7 +1Bsec

    8=

    8=

    8=

    8=

    *C*C

    %ail order

    B=D1=D-= da

    ?orecasts

    %ail*rder

    Value Stream Step 1Acme 3o4 Future State % 3omplete View

    V l St St >

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    Value Stream Step >Generate a Value Stream #lan

    /reate the earl Value Stream Plan

    Tie it to $usiness o$ectives

    Relate the ?uture State Map to our laout

    5hat to do, $ "hen, $ "hom

    ?iF the o$vious

    roken euipment, needed maintenance

    Purchase small tools, replace homemade (iFtures

    0S

    reak the implementation into steps

    reak our (uture state into 'loops)

    Each loop contains the (lo" up to and including a supermarket

    Value Stream Step >

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    Pacemaker Loop

    Stamping

    Loop

    Supplier Loop

    Value Stream Step >Acme6s Value Stream oops

    Value Stream Step >

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    Value Stream Step >51ample Value Stream #lan

    Value Stream Step :

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    Value Stream Step :Start Making the $mprovements

    Make continuous Value Stream Improvement the responsi$ilit

    o( management

    %onKt "ait to get our (uture state map per(ect

    The main point is A/3IEVIQH the (uture state

    Value Stream Step B

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    Value Stream Step B3on!uct Value Stream 7eviews

    Make continuous Value Stream Improvement the responsi$ilit

    o( management

    /onduct regular Value Stream Revie"s "hile "alking the (loor

    Value Stream Manager and Plant Manager

    ?ocus on o$stacles to implementation

    Value Stream Step B

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    Ass

    Stamping

    /oilsSuggestions2

    Revie" "alking the (lo"

    /oncentrate on the pro$lems

    Value Stream Step B51ample Value Stream 7eview

    GuiN 1

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    GuiN 1/ircle the $est ans"er

    %, Creating

    A4 To document the current state (or (uture re(erence

    4 To create a (uture state diagram

    /4 To implement a (uture state "ith less "aste

    %4 To reduce sta((ing in the production environment

    Value Stream Step +=

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    Value Stream Step +=7epeat the 3ycle

    eep "orking (or per(ection

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    5hat /an e Achieved6

    >0; o( "asted steps eliminated

    Throughput time shrinks to less than +=; o( current state time

    %emand ampli(ication is eliminated

    Gualit higher and consistent (rom start to (inish

    Transport links and in(ormation needs shrink dramaticall

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    /oncluding /omments

    A (uture state canKt $e implemented all at once

    aiNen events help "ork to"ards the (uture state

    Value Stream Mapping2

    3elps ou visualise more than a single process level

    Links the material and in(ormation (lo"s

    Provides a common language

    Provides a $lueprint (or implementation

    /an $e more use(ul than uantitative tools

    Ties together lean concepts and techniues

    Revie" o( Hoals

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    Revie" o( Hoalsand EFpectations

    To introduce Value Stream Mapping VSM!

    To dra" a current state map

    Learn the mapping concepts and icons

    To $e a$le to design an improved value stream

    %evelop the a$ilit to 'see the (lo") o( a value stream

    To dra" a (uture state map

    Learn the mapping concepts and icons

    3 k A i t

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    3ome"ork Assignment

    %, Summari=e the steps to ;e ta9en in orer to achie

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    Guestions6 /omments6


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